Method for slush molding articles, of two or more colors from thermoplastic, thermosetting or elastomeric resins in powder form

Abstract

An apparatus including of a mold for slush molding articles of a least two colors; a tank; a separation wall disposed in the tank and dividing the tank into two spaces; a gasket mounted on a free edge of the separation wall which faces the mold, the gasket having a plurality of rigid inserts disposed therein in a predetermined distribution; and an actuator device which expands and retracts the rigid inserts thereby correspondingly expanding and retracting the gasket. A method for slush molding utilizes the apparatus.

What is claimed is: 
     
       1. A method of making a molded two-colored article comprising the steps of: a) providing a mold having an inner surface;   b) providing a gasket having a profile which is approximately the same as a profile of a corresponding region of the mold inner surface;   c) providing rigid material inserts in the gasket;   d) fixing the gasket to a separation wall;   e) inserting the gasket and the separation wall into the mold, and aligning the gasket along the corresponding region of the mold inner surface to create a seal between the mold inner surface and the separation wall and to define first and second half-spaces within the mold that are sealed from each other;   f) compressing the gasket against the corresponding region of the mold utilizing a mechanical device operatively engaging the rigid inserts;   g) slush molding a layer of a first colored material within the first half-space, the layer of the first colored material only adhering to walls defining the first half-space;   h) consolidating the layer of the first colored material;   i) removing the gasket and the separation wall from the mold; and   j) slush molding a continuous layer of a second colored material within the mold, thereby producing the molded two-colored article which includes the layer of the first colored material, the continuous layer of the second colored material, and a separation line between the layer of the first colored material and the continuous layer of the second colored material.   
     
     
       2. A method as recited in claim 1, further comprising distributing thrust of the compressing step along the gasket via the rigid inserts disposed in the gasket and controllably compressing and retracting the gasket via an actuator control device which operatively engages the rigid inserts. 
     
     
       3. A method as recited in claim 2, further comprising engaging the actuator control device with portions of the rigid inserts that project outward from the gasket. 
     
     
       4. A method as recited in claim 2, further comprising engaging a piston of the actuator control device with a plate connected to the rigid inserts and controllably compressing and retracting the gasket by moving the piston. 
     
     
       5. A method, of making a molded two-colored article comprising the steps of: a) providing a mold having an inner surface;   b) providing a gasket having a profile which is approximately the same as a profile of a corresponding region of the mold inner surface;   c) providing rigid material inserts in the gasket;   d) fixing the gasket to a separation wall;   e) inserting the gasket and the separation wall into the mold, and aligning the gasket along the corresponding region of the mold inner surface to create a seal between the mold inner surface and the separation wall and to define first and second half-spaces within the mold that are sealed from each other;   f) compressing the gasket against the corresponding region of the mold utilizing a mechanical device;   g) slush molding a layer of a first colored material within the first half-space, the layer of the first colored material only adhering to walls defining the first half-space;   h) consolidating the layer of the first colored material;   i) removing the gasket and the separation wall from the mold; and   j) slush molding a continuous layer of a second colored material within the mold, thereby producing the molded two-colored article which includes the layer of the first colored material, the continuous layer of the second colored material, and a separation line between the layer of the first colored material and the continuous layer of the second colored material;   further comprising distributing thrust of the compressing step along the gasket via the rigid inserts disposed in the gasket and controllably compressing and retracting the gasket via an actuator control device which operatively engages the rigid inserts; and   further comprising interposing an elastic seal between the gasket and the separation wall in an area where the actuator control device engages the rigid inserts, thereby maintaining sealing between the first and second half-spaces in the area during compressing and retracting of the gasket.